US20180371623A1 - Method for smoothing surface roughness of components - Google Patents
Method for smoothing surface roughness of components Download PDFInfo
- Publication number
- US20180371623A1 US20180371623A1 US15/631,803 US201715631803A US2018371623A1 US 20180371623 A1 US20180371623 A1 US 20180371623A1 US 201715631803 A US201715631803 A US 201715631803A US 2018371623 A1 US2018371623 A1 US 2018371623A1
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- US
- United States
- Prior art keywords
- component
- partially attached
- reactive material
- solution
- aluminum
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- 238000000034 method Methods 0.000 title claims abstract description 36
- 230000003746 surface roughness Effects 0.000 title claims abstract description 9
- 238000009499 grossing Methods 0.000 title description 6
- 239000002245 particle Substances 0.000 claims abstract description 51
- 239000000463 material Substances 0.000 claims abstract description 49
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 34
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 34
- 238000009792 diffusion process Methods 0.000 claims abstract description 27
- 238000004519 manufacturing process Methods 0.000 claims abstract description 11
- 239000000654 additive Substances 0.000 claims abstract description 10
- 230000000996 additive effect Effects 0.000 claims abstract description 10
- 239000000243 solution Substances 0.000 claims description 29
- 238000005137 deposition process Methods 0.000 claims description 8
- 229910000990 Ni alloy Inorganic materials 0.000 claims description 7
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 claims description 6
- 229910017604 nitric acid Inorganic materials 0.000 claims description 6
- 239000003929 acidic solution Substances 0.000 claims description 5
- WKBOTKDWSSQWDR-UHFFFAOYSA-N Bromine atom Chemical compound [Br] WKBOTKDWSSQWDR-UHFFFAOYSA-N 0.000 claims description 3
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 3
- GDTBXPJZTBHREO-UHFFFAOYSA-N bromine Substances BrBr GDTBXPJZTBHREO-UHFFFAOYSA-N 0.000 claims description 3
- 229910052794 bromium Inorganic materials 0.000 claims description 3
- 229910052804 chromium Inorganic materials 0.000 claims description 3
- 239000011651 chromium Substances 0.000 claims description 3
- 229910052710 silicon Inorganic materials 0.000 claims description 3
- 239000010703 silicon Substances 0.000 claims description 3
- 229910052718 tin Inorganic materials 0.000 claims description 3
- 239000011135 tin Substances 0.000 claims description 3
- 239000010936 titanium Substances 0.000 claims description 3
- 229910052719 titanium Inorganic materials 0.000 claims description 3
- 229910052727 yttrium Inorganic materials 0.000 claims description 3
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 claims description 3
- 239000011701 zinc Substances 0.000 claims description 3
- 229910052725 zinc Inorganic materials 0.000 claims description 3
- 238000001816 cooling Methods 0.000 description 5
- 238000004090 dissolution Methods 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 238000007499 fusion processing Methods 0.000 description 2
- 238000005229 chemical vapour deposition Methods 0.000 description 1
- 238000007596 consolidation process Methods 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000002848 electrochemical method Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 235000019592 roughness Nutrition 0.000 description 1
Images
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C10/28—Solid state diffusion of only metal elements or silicon into metallic material surfaces using solids, e.g. powders, pastes
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- B44C1/20—Applying plastic materials and superficially modelling the surface of these materials
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C16/12—Deposition of aluminium only
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
- C23C16/455—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating characterised by the method used for introducing gases into reaction chamber or for modifying gas flows in reaction chamber
- C23C16/45502—Flow conditions in reaction chamber
- C23C16/45504—Laminar flow
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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- C—CHEMISTRY; METALLURGY
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- C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
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- B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05B—INDEXING SCHEME RELATING TO WIND, SPRING, WEIGHT, INERTIA OR LIKE MOTORS, TO MACHINES OR ENGINES FOR LIQUIDS COVERED BY SUBCLASSES F03B, F03D AND F03G
- F05B2250/00—Geometry
- F05B2250/60—Structure; Surface texture
- F05B2250/62—Structure; Surface texture smooth
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/50—Intrinsic material properties or characteristics
- F05D2300/516—Surface roughness
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- This disclosure relates to a method of reducing the surface roughness.
- Additively manufactured components often include excessive surface roughness from satellite particles or surface asperities that occurring from incomplete consolidation at the component surface. Satellite particles can detach and cause damage to other surrounding components. Smoothing of such roughnesses can be difficult, especially in internal passages, blind holes, or other non-line-of-sight surfaces.
- a method for reducing surface roughness of a component includes forming a layer of reactive material on a surface of a component, the surface of the component having at least one partially attached particle, whereby the reactive material substantially covers the at least one partially attached particle, and dissolving the reactive material, wherein dissolving the reactive material covering the partially attached particles causes the partially attached particles to break free from the surface of the component, leaving a new smooth surface.
- the component includes an internal feature, and the internal feature includes a non-line-of-sight surface.
- the at least one partially attached particle is on the non-line-of-sight surface.
- a further embodiment of any of the foregoing embodiments includes conveying a solution through the internal features during the dissolving step.
- the solution dissolves the reactive material.
- the solution is inert with respect to the component.
- the reactive material is an element selected from one of aluminum, bromine, silicon, chromium, zinc, tin, titanium, yttrium, or any combination thereof.
- the reactive material is aluminum and the component comprises a nickel alloy.
- a further embodiment of any of the foregoing embodiments includes forming the component by additive manufacturing.
- the at least one partially attached particle is one of a partially melted particle and a partially sintered particle.
- a further embodiment of any of the foregoing embodiments includes heat treating the component to cause diffusion of the reactive material into a diffusion zone.
- the dissolving step dissolves away the layer of reactive material and the diffusion zone.
- forming the layer of reactive material is accomplished by a gas phase deposition process.
- the gas phase deposition process including flowing gas containing the reactive material in a laminar flow.
- the dissolving step is accomplished with an acidic solution.
- the acidic solution is a 20%-50% solution of nitric acid.
- the dissolving step is performed at a temperature of between about 90 and 100° F. (32.2 and 37.8° C.).
- a method for reducing surface roughness of an engine component includes forming a component by additive manufacturing, the component including an internal feature having at least one rough area, the rough area including at least one partially attached particle, forming an aluminum layer on the surface of the component, the aluminum layer substantially covering the at least one partially attached particle, heat treating the component to cause diffusion of aluminum in a diffusion zone, and dissolving away the aluminum layer and diffusion zone, wherein dissolving the aluminum covering the at least one partially attached particle and the diffusion zone causes the at least one partially attached particle to be freed from the surface of the component.
- the component is a nickel alloy component.
- forming the aluminum layer is accomplished by a gas phase deposition process.
- a further embodiment of any of the foregoing embodiments includes conveying a solution through the internal features during the dissolving step, wherein the solution dissolves the aluminum.
- the solution does not react with the component.
- the solution is a 20%-50% solution of nitric acid, and wherein the dissolving step is performed at a temperature of between about 90 and 100° F. (32.2 and 37.8° C.).
- FIG. 1 schematically shows a component with rough areas.
- FIG. 2 schematically shows a method of smoothing the component.
- FIG. 3 schematically shows a surface of the component with a reactive layer.
- FIG. 1 is a schematic view of an example component 20 with internal features 22 .
- the component 20 is a heat exchanger and the internal features 22 are cooling passages, lattice structures, blind holes, or the like.
- the component 20 can alternatively be any type of gas turbine engine component, such a fuel nozzle, airfoil, combustor liner, another hollow part, or even a non-engine component.
- the component 20 is formed by an additive manufacturing process, such as a powder-bed fusion process. This process creates rough areas or surfaces 24 .
- the additive manufacturing process results in partially melted and solidified powder at the interface of a powder bed and a laser beam during the power-bed fusion process. This partially melted and solidified powder forms rough surfaces or areas 24 .
- rough surfaces or areas 24 include partially sintered areas. This disclosure is not limited to components produced by additive manufacturing and other processes that produce rough surfaces may also benefit.
- the rough areas 24 can be on an outer surface 28 of the component 20 or on non-line-of-sight surfaces 30 of the internal features 22 , which are particularly challenging to access.
- some of the rough areas 24 include particles 26 that are partially attached to the component 20 , known as “satellite particles.”
- the satellite attached particles 26 are partially melted particles or partially sintered particles left behind during additive manufacturing of component 20 , as discussed above.
- the component 20 is a heat exchanger and internal features 22 are cooling passages
- satellite particles 26 can be liberated from the heat exchanger 20 during operation and can damage other parts of the heat exchanger 20 and/or other adjacent components.
- rough areas 24 within cooling passages 22 cause excessive pressure drop of fluid flowing through the cooling passages 22 , which reduces the cooling efficiency of the heat exchanger 20 and reduces the fatigue life of the heat exchanger 20 .
- FIG. 2 shows a method 100 of smoothing the rough areas 24 of the component 20 .
- a layer 32 of reactive material is formed on the rough areas 24 of the component 20 .
- FIG. 3 shows a layer 32 of reactive material on a non-line-of-sight surface 30 with a satellite particle 26 .
- the reactive material is more reactive than the material of the component 20 . That is, a reaction can be induced with the reactive material but not with the material of the component 20 , it least to a substantially lesser extent. This enables the reactive material to be removed without disturbing or affecting the material of the component 20 , as will be discussed further below.
- the dissolution rate of the reactive material is at least ten times greater than the dissolution rate of the material of the component 20 .
- the dissolution rate of the reactive material is 100 times greater than the dissolution rate of the material of the component 20 .
- the component 20 discussed herein is a nickel alloy, which is relatively inert, and the reactive material is aluminum.
- the reactive material can include any of aluminum, bromine, silicon, chromium, zinc, tin, titanium, yttrium, any combination thereof, or another reactive element.
- the aluminum is applied to the component 20 by a gas phase deposition process, such as Chemical Vapor Deposition (“CVD”), to form the reactive layer 32 .
- CVD Chemical Vapor Deposition
- the aluminum is applied by chlorine-catalyzed CVD of aluminum vapor.
- Gas phase deposition processes typically involve flowing gas with a material to be deposited (in this example, aluminum) into a chamber containing the component 20 .
- the gas flow is laminar.
- the Reynolds number is less than about 2300 Laminar flow allows for more concentrated deposition of aluminum on high points (such as rough areas 24 and satellite particles 26 ) of the surfaces 28 , 30 of the component 20 . This in turn ensures the satellite particles 26 are substantially covered by the reactive material.
- the component 20 with the reactive layer 32 is heat treated.
- Heat treatment can be performed by any known method, and the parameters of the heat treatment will depend on the material of the component 20 and the reactive layer 32 .
- the heat treatment causes diffusion of the component 20 material and the reactive layer 32 material into a diffusion zone 34 ( FIG. 3 ).
- the diffusion zone 34 contains a mixture of nickel and aluminum.
- the reactive layer 32 and diffusion zone 34 are present over the satellite particles 26 .
- step 106 component 20 is exposed to a solution that reacts with the reactive material in the reactive layer 32 and the diffusion zone 34 to remove the reactive layer 32 and the diffusion zone 34 .
- the solution is an acidic solution, such as a nitric acid solution. More particularly, the solution is a 20%-50% nitric acid solution.
- the solution reacts with the aluminum whereby aluminum-rich areas of the component 20 are dissolved away, including the diffusion zone 34 and the reactive layer 32 .
- the satellite particles 26 are only partially attached to the surfaces 28 , 30 of the component 20 .
- the satellite particles 26 are substantially covered by the reactive layer 32 and diffusion zone 34 .
- the reactive layer 32 and diffusion zone 34 are dissolved away, the satellite particles 26 break free from the surface 28 , 30 of the component to expose a new smoother surface.
- the freed particles 26 are carried away by the solution. This is especially effective if good coverage of the satellite particles 26 is achieved by laminar flow CVD, as discussed above. This results in smoothing of rough areas 24 .
- Exposure to the solution can include flowing the solution through the internal features 22 of the component 20 . This allows the dissolving process and satellite particle removal 26 to occur on non-line-of-sight surfaces 30 .
- the removal step does not affect the underlying nickel alloy of the component 20 because the nickel alloy is inert with respect to the solution, or at least substantially less reactive than the aluminum.
- the component 20 is exposed to the solution at an elevated temperature. More particularly, the exposure occurs at about 90-100° F. (32.2-37.8° C.).
- the method discussed above results in smoothing of outer surfaces 28 and non-line-of-sight surfaces 30 of the component 20 without damaging or altering the material of the component 20 , which improves the service life as well as tensile and fatigue properties of the component 20 .
- the method can be used to smooth non-line-of-sight surfaces 30 , which are difficult to smooth by other methods (such as electrochemical methods or employing abrasive media), particularly where the internal features 22 have complex or convoluted shapes. This in turn results in time and costs savings for manufacturing components with internal features.
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Abstract
Description
- This disclosure relates to a method of reducing the surface roughness.
- Additively manufactured components often include excessive surface roughness from satellite particles or surface asperities that occurring from incomplete consolidation at the component surface. Satellite particles can detach and cause damage to other surrounding components. Smoothing of such roughnesses can be difficult, especially in internal passages, blind holes, or other non-line-of-sight surfaces.
- A method for reducing surface roughness of a component according to an example of the present disclosure includes forming a layer of reactive material on a surface of a component, the surface of the component having at least one partially attached particle, whereby the reactive material substantially covers the at least one partially attached particle, and dissolving the reactive material, wherein dissolving the reactive material covering the partially attached particles causes the partially attached particles to break free from the surface of the component, leaving a new smooth surface.
- In a further embodiment of the foregoing embodiment, the component includes an internal feature, and the internal feature includes a non-line-of-sight surface.
- In a further embodiment of any of the foregoing embodiments, the at least one partially attached particle is on the non-line-of-sight surface.
- A further embodiment of any of the foregoing embodiments includes conveying a solution through the internal features during the dissolving step. The solution dissolves the reactive material.
- In a further embodiment of any of the foregoing embodiments, the solution is inert with respect to the component.
- In a further embodiment of any of the foregoing embodiments, the reactive material is an element selected from one of aluminum, bromine, silicon, chromium, zinc, tin, titanium, yttrium, or any combination thereof.
- In a further embodiment of any of the foregoing embodiments, the reactive material is aluminum and the component comprises a nickel alloy.
- A further embodiment of any of the foregoing embodiments includes forming the component by additive manufacturing. The at least one partially attached particle is one of a partially melted particle and a partially sintered particle.
- A further embodiment of any of the foregoing embodiments includes heat treating the component to cause diffusion of the reactive material into a diffusion zone.
- In a further embodiment of any of the foregoing embodiments, the dissolving step dissolves away the layer of reactive material and the diffusion zone.
- In a further embodiment of any of the foregoing embodiments, forming the layer of reactive material is accomplished by a gas phase deposition process.
- In a further embodiment of any of the foregoing embodiments, the gas phase deposition process including flowing gas containing the reactive material in a laminar flow.
- In a further embodiment of any of the foregoing embodiments, the dissolving step is accomplished with an acidic solution.
- In a further embodiment of any of the foregoing embodiments, the acidic solution is a 20%-50% solution of nitric acid. The dissolving step is performed at a temperature of between about 90 and 100° F. (32.2 and 37.8° C.).
- A method for reducing surface roughness of an engine component according to an example of the present disclosure includes forming a component by additive manufacturing, the component including an internal feature having at least one rough area, the rough area including at least one partially attached particle, forming an aluminum layer on the surface of the component, the aluminum layer substantially covering the at least one partially attached particle, heat treating the component to cause diffusion of aluminum in a diffusion zone, and dissolving away the aluminum layer and diffusion zone, wherein dissolving the aluminum covering the at least one partially attached particle and the diffusion zone causes the at least one partially attached particle to be freed from the surface of the component.
- In a further embodiment of any of the foregoing embodiments, the component is a nickel alloy component.
- In a further embodiment of any of the foregoing embodiments, forming the aluminum layer is accomplished by a gas phase deposition process.
- A further embodiment of any of the foregoing embodiments includes conveying a solution through the internal features during the dissolving step, wherein the solution dissolves the aluminum.
- In a further embodiment of any of the foregoing embodiments, the solution does not react with the component.
- In a further embodiment of any of the foregoing embodiments, the solution is a 20%-50% solution of nitric acid, and wherein the dissolving step is performed at a temperature of between about 90 and 100° F. (32.2 and 37.8° C.).
-
FIG. 1 schematically shows a component with rough areas. -
FIG. 2 schematically shows a method of smoothing the component. -
FIG. 3 schematically shows a surface of the component with a reactive layer. -
FIG. 1 is a schematic view of anexample component 20 withinternal features 22. As an example, thecomponent 20 is a heat exchanger and theinternal features 22 are cooling passages, lattice structures, blind holes, or the like. However, thecomponent 20 can alternatively be any type of gas turbine engine component, such a fuel nozzle, airfoil, combustor liner, another hollow part, or even a non-engine component. - The
component 20 is formed by an additive manufacturing process, such as a powder-bed fusion process. This process creates rough areas orsurfaces 24. For instance, the additive manufacturing process results in partially melted and solidified powder at the interface of a powder bed and a laser beam during the power-bed fusion process. This partially melted and solidified powder forms rough surfaces orareas 24. In another example, rough surfaces orareas 24 include partially sintered areas. This disclosure is not limited to components produced by additive manufacturing and other processes that produce rough surfaces may also benefit. Therough areas 24 can be on anouter surface 28 of thecomponent 20 or on non-line-of-sight surfaces 30 of theinternal features 22, which are particularly challenging to access. In one example, some of therough areas 24 includeparticles 26 that are partially attached to thecomponent 20, known as “satellite particles.” In one example, the satellite attachedparticles 26 are partially melted particles or partially sintered particles left behind during additive manufacturing ofcomponent 20, as discussed above. - In the case where the
component 20 is a heat exchanger andinternal features 22 are cooling passages,satellite particles 26 can be liberated from theheat exchanger 20 during operation and can damage other parts of theheat exchanger 20 and/or other adjacent components. Also,rough areas 24 withincooling passages 22 cause excessive pressure drop of fluid flowing through thecooling passages 22, which reduces the cooling efficiency of theheat exchanger 20 and reduces the fatigue life of theheat exchanger 20. -
FIG. 2 shows amethod 100 of smoothing therough areas 24 of thecomponent 20. Instep 102, alayer 32 of reactive material is formed on therough areas 24 of thecomponent 20.FIG. 3 shows alayer 32 of reactive material on a non-line-of-sight surface 30 with asatellite particle 26. The reactive material is more reactive than the material of thecomponent 20. That is, a reaction can be induced with the reactive material but not with the material of thecomponent 20, it least to a substantially lesser extent. This enables the reactive material to be removed without disturbing or affecting the material of thecomponent 20, as will be discussed further below. In one example, the dissolution rate of the reactive material is at least ten times greater than the dissolution rate of the material of thecomponent 20. In a further example, the dissolution rate of the reactive material is 100 times greater than the dissolution rate of the material of thecomponent 20. - For example, the
component 20 discussed herein is a nickel alloy, which is relatively inert, and the reactive material is aluminum. However, it should be understood thatother component 20 materials and reactive materials can be used. For instance, the reactive material can include any of aluminum, bromine, silicon, chromium, zinc, tin, titanium, yttrium, any combination thereof, or another reactive element. - The aluminum is applied to the
component 20 by a gas phase deposition process, such as Chemical Vapor Deposition (“CVD”), to form thereactive layer 32. In a particular example, the aluminum is applied by chlorine-catalyzed CVD of aluminum vapor. Gas phase deposition processes typically involve flowing gas with a material to be deposited (in this example, aluminum) into a chamber containing thecomponent 20. In one example, the gas flow is laminar. For instance, the Reynolds number is less than about 2300 Laminar flow allows for more concentrated deposition of aluminum on high points (such asrough areas 24 and satellite particles 26) of thesurfaces component 20. This in turn ensures thesatellite particles 26 are substantially covered by the reactive material. - Referring again to
FIG. 2 , instep 104, thecomponent 20 with thereactive layer 32 is heat treated. Heat treatment can be performed by any known method, and the parameters of the heat treatment will depend on the material of thecomponent 20 and thereactive layer 32. The heat treatment causes diffusion of thecomponent 20 material and thereactive layer 32 material into a diffusion zone 34 (FIG. 3 ). In the present example, thediffusion zone 34 contains a mixture of nickel and aluminum. Importantly, thereactive layer 32 anddiffusion zone 34 are present over thesatellite particles 26. - In
step 106,component 20 is exposed to a solution that reacts with the reactive material in thereactive layer 32 and thediffusion zone 34 to remove thereactive layer 32 and thediffusion zone 34. In one example, the solution is an acidic solution, such as a nitric acid solution. More particularly, the solution is a 20%-50% nitric acid solution. The solution reacts with the aluminum whereby aluminum-rich areas of thecomponent 20 are dissolved away, including thediffusion zone 34 and thereactive layer 32. - As discussed above, the
satellite particles 26 are only partially attached to thesurfaces component 20. In this dissolving process, thesatellite particles 26 are substantially covered by thereactive layer 32 anddiffusion zone 34. As thereactive layer 32 anddiffusion zone 34 are dissolved away, thesatellite particles 26 break free from thesurface particles 26 are carried away by the solution. This is especially effective if good coverage of thesatellite particles 26 is achieved by laminar flow CVD, as discussed above. This results in smoothing ofrough areas 24. Exposure to the solution can include flowing the solution through theinternal features 22 of thecomponent 20. This allows the dissolving process andsatellite particle removal 26 to occur on non-line-of-sight surfaces 30. The removal step does not affect the underlying nickel alloy of thecomponent 20 because the nickel alloy is inert with respect to the solution, or at least substantially less reactive than the aluminum. - In one example, during
step 106, thecomponent 20 is exposed to the solution at an elevated temperature. More particularly, the exposure occurs at about 90-100° F. (32.2-37.8° C.). - The method discussed above results in smoothing of
outer surfaces 28 and non-line-of-sight surfaces 30 of thecomponent 20 without damaging or altering the material of thecomponent 20, which improves the service life as well as tensile and fatigue properties of thecomponent 20. Furthermore, the method can be used to smooth non-line-of-sight surfaces 30, which are difficult to smooth by other methods (such as electrochemical methods or employing abrasive media), particularly where theinternal features 22 have complex or convoluted shapes. This in turn results in time and costs savings for manufacturing components with internal features. - Furthermore, the foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.
Claims (21)
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US15/631,803 US20180371623A1 (en) | 2017-06-23 | 2017-06-23 | Method for smoothing surface roughness of components |
EP18179275.5A EP3418423A1 (en) | 2017-06-23 | 2018-06-22 | Method for smoothing surface roughness of components |
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US15/631,803 US20180371623A1 (en) | 2017-06-23 | 2017-06-23 | Method for smoothing surface roughness of components |
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US20180371623A1 true US20180371623A1 (en) | 2018-12-27 |
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US15/631,803 Abandoned US20180371623A1 (en) | 2017-06-23 | 2017-06-23 | Method for smoothing surface roughness of components |
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US5573862A (en) * | 1992-04-13 | 1996-11-12 | Alliedsignal Inc. | Single crystal oxide turbine blades |
US8506836B2 (en) * | 2011-09-16 | 2013-08-13 | Honeywell International Inc. | Methods for manufacturing components from articles formed by additive-manufacturing processes |
US10030298B2 (en) * | 2015-08-21 | 2018-07-24 | General Electric Company | Method for altering metal surfaces |
US10105798B2 (en) * | 2015-11-05 | 2018-10-23 | Honeywell International Inc. | Surface improvement of additively manufactured articles produced with aluminum alloys |
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